Feb 1, 1995 ... increasingly slack demand until the production lines of both firms are refitted for
the HFC-. 134a heat ..... and brazed together in a vacuum, utilizing noncorrosive
flux process. - PLATE & FIN ..... Chrysler LeBaron. Right/Left End ...
Public Disclosure Authorized
Document of
The World Bank FOR OFFICIAL USE ONLY
Public Disclosure Authorized
Public Disclosure Authorized
Public Disclosure Authorized
Report No. 13737-VE MEMORANDUM AND RECOMMENDATION OF THE DIRECTOR FOR COUNTRYDEPARTMENTII TO THE REGIONAL VICE PRESIDENT,
LATIN AMERICA AND CARIBBEAN REGION OF THE
INTERNATIONAL BANK FOR RECONSTRUCTIONAND DEVELOPMENT ON A PROPOSED OZONE PROJECTS TRUST FUND GRANT IN AN AMOUNTEQUIVALENT TO US$3.1 MILLION TO VENEZUELANPRIVATE ENTERPRISE FABRICA DE APARATOS DE AIRE ACONDICIONADO, C.A. (FAACA), FOR A MOBILE AIR CONDITIONER (MAC) FACTORY CONVERSION PROJECT FOR FABRICATION OF HFC-134a
FEBRUARY 8,
HEAT EXCHANGERS
1995
Environment and Urban Development Division Country Department II Latin America and the Caribbean Region Office This document has a restricted distribution and may be used by recipients only in the performance of their official duties. Its contents may not otherwise be disclosed without World Bank authorization.
CURRENCY EQUIVALENTS Currency Unit = Venezuelan Bolivar (BS) US$1.00 = 169.6 Bs (Exchange rate as of February 8, 1995) UNITS AND MEASURES metric ton - Ton (T) = 1,000 kg.
ACRONYMS AAC
Automobile Air Conditioning
:
Air Conditioning
AC CCL4
Carbon Tetrachloride, a controlled ODS
:
CFCs
Chlorofluorocarbons
FONDO[N
Foundation to Implement the Montreal Protocol in Venezuela
GOV
:
Government of Venezuela
HCFC
:
Hydrochlorofluorocarbon
HFC
:
Hydrofluorocarbon
MAC
:
Mobile Air Conditioner
MCF
:
Methyl chloroform, a controlled ODS Multilateral Fund Executive Committee
MFEC MFMP
:
Multilateral Fund for the Implementation of the Montreal Protocol Montreal Protocol on Substances that Deplete the Ozone Layer
MP
ODS
:
Ozone Depleting Substances
OORG
:
Ozone Operations Resource Group Ozone Projects Trust Fund
OTF USEPA
:
United States Environmental Protection Agency
FISCALYEAR January 1 - December 31
FOROFFICIALUSE ONLY
VENEZUELA AIR CONDITIONING CFC-12 TO HFC-134-a CONVERSION PROJECT
Project and Grant Summary Financial Agent
None. Direct disbursement from the Bank to the Beneficiary.
Guarantor
None. Guarantor not required - OTF grant to GOV.
Executing Agencies
The Beneficiary under the supervision of the World Bank and FONDOIN.
Beneficiaries
Fabrica de Aparatos de Aire Acondicionado, C.A. (FAACA)
Poverty
N/A
Amount
US$3. 1 million (Incremental Cost)
Terms
Grant
Estimated ODS Consumption Eliminated
90 tons annually (Basis; 35,000 units/yr production)
Finan
See Schedule A
Plan
Cost Eflectiveness
Unit Abatement Cost: $5.01/kg/year (Basis: incremental costs only)
Economic Rate of Return
N/A
Staff praisal Report
N/A
Thisdocumenthasa restricteddistribution andmaybe usedby recipientsonly in the performance of their
| official duties. Its contcnts may not otherwisebe disclosed without WorldBank authorization.l
I
MEMORANDUM AND RECOMMENDATION OF THE DIRECTOR FOR COtJNTRY DEPARTMENT II TO THE REGIONAL VICE PRESIDENT, LATIN AMERICA AND CARIBBEAN REGION OF THE INTERNATIONAL BANK FOR RECONSTRUCTION AND DEVELOPMENT ON A PROPOSED OZONE PROJECTS TRUST FUND GRANT IN AN AMOUNT EQUIVALENT TO US$3 I MILLION TO THE VENEZUELAN PRIVATE ENTERPRISE FABRICA DE APARATOS DE AIRE ACONDICIONADO (FAACA), FOR A MOBILE AIR CONDITIONER (MAC) FACTORY CONVERSION PROJECT FOR FABRICATION OF HFC- I 34a HEAT EXCHANGERS
I submit for your approval the following memorandum and recommendation on a 1. proposed Ozone Projects Trust Fund (OTF) grant which will be disbursed to Fabrica de Aparatos de Aire Acondicionado (FAACA), an auto air conditioner (MAC) fabricator, to finance the incremental costs associated with the retooling of a heat exchanger fabrication and assembly line, and related training and technical assistance costs. A grant amount of US$3.48 million for this project was approved by the Multilateral Fund Executive Committee (MiFEC)at its November 1993 meeting. Only US$3.1 millionwill now be requested, due to a lower revised project cost estimate during appraisal. The project will be the third Bank executed Montreal Protocol (MP) grant to Venezuela and will fund a key activity to reduce Venezuela's consumption of ODSs. An OTF grant agreement will be entered into directly between the Bank as OTF trustee and FAACA as the Recipient. Estimated ODS eliminatedby the project is 91,000 kg. annually. Venezuela Ozone Depleting Substance (ODS) Sector Background. Venezuela 2. signed the Montreal Protocol on September 16, 1987, and ratified it on February 6, 1989. As an Article 5 signatory (annual per capita ODS consumption of less than 300 grams), Venezuela is eligible for OTF support. ODSs are produced in six developing nations, Argentina, Brazil, China, India, Mexico, and Venezuela. Total production of CFCs and MCF in these nations in 1989 was approximately 70,000 tons, of which Venezuela's share was 4150 tons, or 6%. MCF consumption in 1991 was 130 tons, down from 570 tons in 1990. All CC14 (1350 tons in 1991) is used as a chemical intermediate feed stock. CFC/Halon consumption in Venezuela in 1990 was 3420 tons, but rose to 3820 tons in 1991, still a decrease of 12% since 1986. Distribution of ODSs by end use in 1991 was MACs 25%; other AC/refrigeration 52%; foaming agent 16%; aerosols 4%, Halon fire extinguisher 1%; and solvents 2%. Of the AC/refrigeration share, an estimated 80% was for aftermarket use for servicing and leak replacement. The 1992 consumption in the automobile and truck air conditioner (MAC) sector was estimated at 80 tons for newly assembled cars, and 900 tons for aftermarket use. Per capita annual consumption of CFCs decreased from 270 grams in 1986 to 170 grams in 1990. A breakdown of estimated CFC12 consumption for 1992 in the AC/refrigeration subsectors and more detailed national data are available in the Project File. ODS Phase-Out Strategy for the Mobile Air Conditioner (MAC) Subsector. 3. With more than 75% of Venezuela's CFC consumption currently used in AC/refrigerator
-2 applications, these subsectors are the principal focus of the national ODS phase-out strategy. The MAC subsector alone accounts for 25% of national CFC consumption. Venezuela's eight auto assemblers produced 86,000 units in 1992, and imported another 20,000 units already assembled for local sale. An additional44,000 assembly units, including trucks were imported directly, for total 1992 saies of 150,000 new units of all types. The total national automobile inventory of registered vehicles is approximately 1,200,000. An estirnated 60% of new autos and an unknown percentage of the current national inventory have installed MAC systems. Each currently installedunit has an average charge of 1.1 kg. of CFC-12. Two domestic MAC fabricators (FAACA and AAISA) produce a total of approximately 6075,000 MAC units annually', assemblingcompressors and fabricating evaporators and condensers, selling to both assemblers and aftermarket distributors. FAACA's market share is estimated to be between one-half and two-thirds of the total. FAACA produces both complete MACs, including compressors, and heat exchangers which are marketed separately. 1992 CFC-12 consumption in the MAC subsector was estimated at 80 metric tons for testing and charging of systems for newly assembled vehicles, and some 900 tons for aftermarket servicing of all types. Current plans of the auto assemblers for conversion from CFC-12 to HFC-134a refrigerant units call for a transition which will begin as early as August 1993 for one company with the others beginning during 1994. The total transition for new units to HFC-134a is expected to be complete by end 1995. Aftermarket servicing for CFC-12 units will be required for some time afterward. Nevertheless, almost complete phase-out of CFC12 consumptionin the MAC subsector is attainable by 2000. The FAACA factory conversion project, for which OTF funding has been approved, is an integral part of the phase-out strategy. The eight auto assemblers, six of which are 100% foreign owned subsidiaries, will finance their own assembly line conversions, and training of their dealerships for servicing of HFC-134a MAC units. The second MAC fabricator, AAISA, has also presented a factory conversion project for OTF financing which is at an advanced stage of processing by the Bank. FAACA Background. FAACA was founded in 1970 as a member of the 4. MANCIN group. The company employs 350 people in the production of MAC units for most of the eight major automobile assemblersin Venezuela. In 1992, FAACA's estimated share of the Venezuelan market (DomesticProduction plus Imports) for MAC components production by evaporators/condensers and compressors was 53.6% and 38.2% respectively. In 1992, FAACA earned US$106,000 on sales of US$15 million. Net income in 1993 was US$72,000 on sales of US$11 million. The financial statements of the company from 1990 to 1993 are available in the project file. FAACA's profitability figures tend to underestimate its true financialposition, due to the interlockingnature of the MANCIN companies ownership and activities, and the apparent ease with which it is financing non-incremental costs from MANCIN group resources. At past and anticipated future production levels, FAACA has been, and, once converted, will be a viable concern. It should be noted, however, that beginning in calendar year 1994, both FAACA and AAISA will experience increasinglyslack demand until the production lines of both firms are refitted for the HFC134a heat exchangers. Anticipatedproduction levels, which are similar to those of recent
I This statistic is difficult to verify because different numbers of compressors, evaporators and condensers are manufactured, and an equal number of each does not reflect a like number of integrated MAC units.
-3components. The OTF funding requested by FAACA is necessary to enable the firm to carry out this conversion. In the absence of the conversion, FAACA would be forced to cease production in a few years for lack of markets. MAC compressor components are imported and assembled by FAACA. Conversion of this operation is not being submitted for OTF financing. 5. Project Objectives. The primary objective of the project is to enable FAACA to substitute production of HFC-134a MACs for its current product line of CFC-12 MACs. 6. Project Description. The proposed project consists of the retooling of a heat exchanger fabrication and assembly line, and related training and technical assistance costs. The assembly line conversion will permit production of mobile air conditioning (MAC) systems which permit use of HFC-134a rather than CFC-12 as the refrigeration agent. (See Annex 1, Technical and Cost Assessment, for complete project description). A Calorimeter test laboratory for which funding was originally requested, was not found to be an incremental cost, and has been deleted from the project scope. Certain categories of recurrent annual investments related to model changes were also considered to be nonincremental and, likewise, are not included in the project scope. 7. Project Cost and Financing. The project cost estimates at time of presentation to the MFEC were US$4.1 million total, and US$3.48 million incremental. More recent specification has led to significantly reduced tooling costs (US$1.363 vs US$2.067). The adjusted total cost estimate for project implementation, including capital costs, freight, technical assistance and training has decreased to US$3.735 million, including 11% contingency. Eligible incremental costs are US$3.1 million net of taxes, including 11 % contingency. The project cost estimate is summarized in Table 1. FAACA, itself, will finance the US$.629 million in non-incremental costs, including 11 % contingency. Table 1: FAACA Project Cost Estimate (US$ 000's)
Evaporator and Condenser Assembly Lines: Investment: Equipment Costs Tooling Costs Freight Other Incremental Costs Non-incremental Investment by FAACA Total Total with 11% Contingency Eligible Incremental Costs Eligible Incremental Costs Including 11 % Contingency
(US$ 000's) 842 1,363 181 412 567 US$3,365 3,735 2,798 3,105
- 48. Incremental Costs. All plant rearrangements, tooling/equipment, training and product evaluation tests are incremental, as they are required to effect the changeover to production of HFC-134a compatible evaporators and condensers. Resale value of the existing CFC-12 line is negligible, in spite of most equipment and tools having further expected useful life of 5 years or more. Non-incremental investment by FAACA of US$567,330 consists of tooling investments which occur on an annual basis to support new model design changes, whether for CFC-12 or HFC-134a service. Due to their recurring nature, these are not considered incremental. The total incremental cost estimate is therefore US$2.8 million exclusive of contingency. A detailed breakdown of project and incremental costs is given in Tables I-IV of Appendix I of Annex 1. 9. Project Implementation. The project will be implemented during a 24 month period. Project implementation is directly tied to FAACA's customer requirements and introduction of HFC-134a MACs into the marketplace, which in Venezuela is planned for the 1995 model year. (See Appendix I, Table IX, HFC-134a Production at Assembly Plants and Localization Program, for phase-in schedule.) FAACA, itself, will manage the project installation, with internal staff resources, and is considered competent to do so. FONDOIN will assist with administrative liaison and disbursement operations as required. Technical and procurement oversight during installation and start up will be provided by a Bank contracted technical specialist. Procurement and disbursement arrangements will be as indicated in Schedule B. 10. Project Sustainability. The primary purpose of the OTF is to provide a financial incentive to facilitate ODS phase-out by compensating beneficiaries for incremental costs incurred as a result of converting to non-ODS technologies. A further important benefit of the Fund is to permit beneficiary nations to implement phase-out strategies without incurring a process of deindustrialization. ODS phase-out in the MAC sub-sector in Venezuela will take place with or without the MAC projects. Development of local HFC-134a MAC production capacity is essential to retention of MAC production capacity in Venezuela. The grants to FAACA and AAISA will not only permit factory conversion without financial prejudice to the firms, but will, at the same time, ensure continued production of MAC components in Venezuela, and facilitate afternarket servicing of HFC-134a units. 11. Rationale for Montreal Protocol Financing. With or without the project, and that of AAISA, auto assemblers will assemble cars only with HFC-134a compressors after 1996. It is estimated that comnpletetransition of assembly and aftermarket to HFC-134a units will be virtually compe-te in Venezuela by 2000. The integrated program of assembler financed transition, supplemented by OTF subsidies to the two MAC fabricators, will thus result in the elimination of over 25% of current national CFC consumption, while, at the same time, permitting the rxe lbtion of domestic NMACproduction capacity and related employment generation. Given the decision of the auto industry to undertake worldwide conversion, the alternative to project irnplementatioij '.':QUIU be a loss of FAACA and AAISA market share to imports, and evenrtal disappearance of the MAC industry in Venezuela. Protection against deindustrialization associated with the transition to non-ODS technologies is an approved use of OTF resources. 12. Issues and Actions. There aie no major technical issues associated with project implementation. A direct Grant Agreement will be entered into between the Bank and
- 5-
FAACA, analogous to that between the Bank and Plasticos Melanca. S A...due to the absencc of a usable financial intermediary for the Venezuela program. Procurement w,l involve 35-40 small contracts (Schedule B). Approval by the Bank of a financiai plan to tLindnon-incremental project costs will be a condition of negotiations. 13. Environmental Aspects. The elimination of CFC-12 consumption is the basic environmental objective of the conversions. The project will contribute indirectly to elimination of approximately 91,000 kg. of CFC- 12 consumption per year based upon: i) an annual production level of 35,000 units; and ii) an assumed 2.5 kg. of CFC- I2 consumed over the useful life of each CFC-12 MAC to be replaced with a HFC-134a MAC. There are no major environmental issues associated with the installation or operation of the converted assembly lines themselves, other than routine workplace safety measures. The project is classified as category B for environment assessment purposes. 14. Project Benefits. The major environmental benefit of the project is the enabling of FAACA to now produce MAC heat exchangers which use non-ODS HFC- 134a as the refrigerant in place of CFC-12. A secondary environmental benefit is the eliminationof CFC-12 now used and emitted into the atmosphere in the testing of assembled compressors and heat exchangers. The direct economic benefit is the retention in Venezuela of production capacity to supply both assemblers and aftermarket users with HFC- I 34a units, and the associated net savings in foreign exchange earnings, and the employment level retained by avoiding the demise of the local MAC industry. The unit abatement cost associated with CFC- 12 consumption eliminatedby production of HFC-134a MAC units, including CFC consumption eliminatedin the factory, is US$5.01/kg/year based on an annual production level of 35,000 units. Tle calculations and interpretation of results are presented in Annex 2, Calculation of Unit Abatement Costs. 15. Project Risks. There are no significanttechnical project risks, the technologies to be employed having already been proven through application in parent countries of assemblers. There is a potential commercial risk of FAACA being able to compete with imported MAC units and with AAISA for both original equipment and aftermarket shares. The same risks also apply to AAISA. Nevertheless, FAACA is a financiallyviable concern of proven technical and commercialcompetence. The fact that FAACA exports over 20% of its production to Brazil and the U.S.A. would indicate that it has a reasonably competitive cost structure. 16. Technical Evaluation. The Bank's technical assessment consisted of a detailed review of the technical and financial proposals with FAACA, field inspection of existing units and proposed replacement installations, and verification of appropriateness with market demands for assemblers and aftermarket dealers. Annex 1, Technical and Cost Assessment, provides a complete description of the project and associated costs. 17. On the basis of the assessment, the Bank considers the proposals to be of sound technical design, and qualified for OTF grant financing of eligible incremental costs. FAACA is judged to be technically and organizationally capable of implementingthe project.
-6 -
Annex 3, A Technical Opinion, indicates concurrence with the project by the Bank's Ozone Operations Resource Glroup(OORG) technical expert for MAC systems projects. Annex 4 is a copy of the letter from FONDOIN to the MP Secretariat officiallyrequesting the project. Recommendation. I am satisfied that the proposed OTF grant would comply with 18. relevant provisions of the ozone projects trust fund in the Executive Director's resolution No. 91/5, establishing the Global Environment Facility, and I recommend that the Regional Vice President of the LAC region approve the proposed Grant.
Edilberto L. Segura Director, Country Department II Latin America and the Caribbean Region
Attachments Washington D.C. February 8, 1995
-7Schedule A VENEZUELA FAACA Automobile Air Conditioner Factory Conversion Project Estimated Project Cost
Local
Foreign
Total
-------------(US$ thousand)-----------Equipment
120
800
920
Tooling
421
1,045
1,466
Other Incremental
412
412
Recurrent Non-incremental
567
567
Contingency
167
203
370
TOTAL
1,687
2.048
3,735
Financial Plan OTF
Beneficiary2
Total
------------- (US$ thousand)-----------Equipment Tooling Other Incremental Recurrent Non-incremental
920
--
920
1,466
--
1,466
412
--
412
--
567
567
Contingency
308
62
370
TOTAL
3,106
629
3,735
2 Noneligible incremental costs of US$567,330 and the corresponding contingency of approximately 10% will be funded by FAACA itself.
-8Schedule B Page 1 of 2 Procurement and Disbursement
Procurement. Procurement of equipment, tools and dies to produce the evaporators and condensers will be characterized by a large number (35-40 estimated) of relatively small value purchase contracts. Maximum individual contract value is estimated at US$210,000. Local and international shopping, based upon price comparison of at least three eligible suppliers (exceptions may be permitted with adequate justification) will be used. FAACA will carry out the vendor selection, subject to verification by the Bank's technical consultant. The company's normal practice is to procure through competitive shopping. FAACA has already demonstrated, particularly with its reduced project cost reestimate, that it is capable of competently executing competitive shopping procurement procedures. Technical Assistance (T/A) agreements between FAACA and the Harrison Division of the General Motors Corporation and the Sanden Corporation are based on technical data and design specifications for (i) GM Condensers and Air Conditioning Systems required by FAACA to fabricate GM design MACs for the HFC-134a refrigerant; and (ii) Sanden components which satisfy design specifications for the rest of FAACA's product line. The T/A agreement costs have been negotiated with the Harrison Division and Sanden respectively and they fall within the customary range of industry fees and arrangements for technology transfer. The GM license was negotiated before MFEC funding was requested. All OTF financed contracts will be subject to ex-post review by the Bank in order to verify compliance with Bank procurement guidelines.
Procurement Methods (US$ 000's) Category
ICB
LCB
-- Iquipment
--
--
920
920
--
Tooling
--
--
1,466
1,466
--
Technical Assistance
--
--
360
360
Training
--
--
52
52
307
307
--
Unallocated
Other
Total
-9-
Schedule B E'age 2 of 2
Disbursement. The grant is expected to be disbursed xit i n-cr'Axrl of 18 calendar months and the closing date will be June 30, 1997. The Bank will Wshursc agai.nst 100% of eligible foreign expenditure and 100% of eligible local expenditures for l ligible incremental costs, net of direct import, sales and value added taxes, for grant financed goods contracts. In accordance with decision of the MFEC, retroactive financing will be petmitted for eligible expenditures incurred after the date of Venezuela's adhesion to the NMontrealProtocol (February 6, 1989) under contracts signed prior to grant signature whichi are eligible incremental costs. Retroactive financing will amount to an estimated US$755,000 including technical assistance fees and selected equipment and tooling. Disbursements will be made against Statements of Expenditure (SOE), except for requests for direct payments to suppliers/contractors. These direct payment requests should be for amounts above US$30,000 equivalent, and be fully documented. Requests for disbursement will be transmitted by FAACA to the Bank. Payments for eligible retroactive expenditures will be made directly to FAACA. To facilitate project implementation, a Special Account in US dollars for US$300,000 will be opened and maintained in a commercial bank acceptable to the Bank. Estimated Disbursements (US$ 000's) FY95 Annual Cumulative
2,000 2,000
FY96 1,100 3,100
-
10 -
Schedule C
VENEZUELA FAACA - CFC-12 to HFC-134 Conversion Project
Timetable of Key Project Processing Events (a)
Time taken to prepare:
6 months
(b)
Prepared by
Beneficiaryin conjunction with Bank technical consultant
(c)
First Bank mission:
January 1993
(d)
MFEC Approval:
October 1993
(e)
Pre Appraisal:
November 1993
(f)
Appraisal:
May 1994
(h)
RVP Approval:
January 1995
(i)
Planned Signing:
February 1995
(j)
Planned Effectiveness:
February 1995
(k)
Planned Completion:
December 1996
ANNEX 1
FABRICA DE APARATOS DE AIRE ACONDICIONADO C.A. (FAACA)
Automobile Air Conditioner (AAC) Factory Conversion for Production of HFC-134a Refrigerant Mobile Air Conditioners (MACs)
Technical and Cost Assessment By F. Peter Turner
Annex I Page I of 4
PROJECT DESCRIPTION
Evaporator and Condenser Assembly Lines: The project request is the result of new AC component designs required to meet new thermodynamicrequirements that arise in the conversion from CFC-12 to HFC-134a refrigerants. FAACA plans to use the following designs to meet the needs of its customerswhen HFC-134a MACs are introduced in vehicles in the Venezuelan market: EVAPORATORS: - SPT (Serpentinetype): Produced with one straight extruded multiport tube, formed several times to dimension, with corrugated fins between every two tubes and brazed together in a vacuum, utilizing noncorrosiveflux process. - PLATE & FIN type: Produced with several stamped plates joined together to form a flat tube with interposedexternal corrugated fms. All components are brazed together by a vacuum brazing process. This core normally presents two side tanks stamped in the plates which might be located to each side or one side of core. The last configurationwill increase strength, performance and compactness and is known as "U-Flow" type. CONDENSERS: SPT (Serpentinetype): Similar to SPT evaporators but produced with several formed tubes to divide the core in several internal circuits to decrease pressure drop. -
- PF (Parallel Flow type): Produced with several straight microextruded multiport tubes linked with two side vertical tanks that are divided internally to provide several circuits to decrease pressure drop, with interposed external corrugated fins between tubes. All componentswill be joined together by a noncorrosive flux brazing process. There are two different types of PF design which will be used: 1)
Headered Tube Center (HTC) type - Has side tanks that will be manufacturedusing a stamped header and extrusion shaped tank.
Annex I Page 2 of 4
2)
Standard type - Sidetankswill be manufacturedusing a tube mill and will be tubular in shape.
2. Current production designs used in CFC-12 systems will be available locally for Original Entry Market (OEM), Port of Entry (POE) Retrofit, and aftermarket service until 1998. 3. Some of the designs are currently produced, but new requirements mandate designs change to the physical characteristicsof component parts. 4. Design Basis for Equipment and Tooling Requirements: An analysis of FAACA's customer requirements indicatedfour types of design applications for which equipmentand tooling specific to conversionto HFC-134a evaporators/condensersproduction will be required: i) ii)
Carry over models with minor changes in AC system for HFC-134a application (current production). Carry over models with complete AC componentdesign changes for HFC134a change over.
iii)
Car line model substitutionwith complete changes in the AC system.
iv)
New models designed for CFC-12 already submitted for customer validation that need major changes for HFC-134a application.
5. Table V of Appendix 1 summarizes FAACA's customers, vehicle models, reason for design change, and anticipatedvolumes when production of HFC-134a MAC units begins. 6. Table VI of Appendix 1 further explains present/future product designs and their applicationsto customer HFC-134a refrigerant-usingMACs. 7. To develop the equipmentand tooling specificationsfor the cost estimate, customer design change requests were validated, and then the equipment and tools required to manufacture the new designs were reviewed in detail. 8.
Criteria used to review and justify equipment/toolinglists included the following:
Annex I Page 3 of 4
* Were requests consistentwith actual design changes? * Was there duplication of existing tooling and equipment? * Could proposed dies be modified by using inserts thus reducing the number of actual dies used? * Could current tooling be modified to accommodatenew tooling requirements? 9. Appendix 1, Table VII was developed to show the relationshipbetween the Project equipment list (Appendix 1, Table I) and FAACA's customer requirements. Items 8E & 11E will have a major impact in the reduction of CFC-12 and the use of Perchloroethyleneat FAACA's facilities. Also, the total number of customer applications for each required equipment varies due to specific component design requirements. 10. Appendix 1, Table VIII shows the relationship between the Project tooling requirements (Appendix 1, Table II) and FAACA's customer requirements. 11. Estimated Project Costs: Total project costs, exclusive of contingencyand taxes, are estimated at US$2.798 million, disaggregatedinto incremental equipmentand tooling costs plus freight, other incremental costs, and nonincrementalinvestment financedby FAACA. Equipment costs (US$842,000)are itemized in Appendix 1, Table I by equipment type and location of fabrication. Tooling costs (US$1.363million) are itemized in the same manner in Appendix 1, Table II. Other incrementalcosts (US$412,000)consistingof licensing fees and training, are itemized in Appendix 1, Table III. Nonincrementalcosts (US$567,000) which will be financed by FAACA, are detailed in Appendix 1, Table IV. The tooling and training costs noted in Table IV are specific to particular evaporator/condenserdesigns. Nevertheless, annual design changes and subsequentnew tooling requirementsof this type are characteristic of the industry, and would be required on an annual basis, regardless of whether CFC-12 or HFC-134a MACs were being fabricated. FAACA and the Bank agreed, therefore, that such costs are recurrent annual capital costs rather than incremental costs, and thus not eligible for OTF financing. 12. CFC ConsumptionEliminated: This project offers the opportunityto eliminate both the direct use of CFC-12 and CFC-11 at FAACA's production facility, and indirectly, the initial and replacement charges of CFC-12 which would be used in each MAC fabricated by FAACA, in the absence of the conversionto production of HFC-134aheat exchangers. CFC-12 is used directly as a test media in the manufacture of evaporators and condensers, whereas CFC-11 is used to internally flush AC systems/componentsin the engineering and
Annex I Page 4 of 4
garage facilities. Direct use of CFC-11 will be elimninatedwhen recycle/reclaim/recharge equipment, currently on order, is delivered and its use implementedby the engineering/shop groups. 13. CFC-12 will be completely eliminated when new condenser/evaporatorlines are installed. The new process uses a helium based mass-spectrometertest procedure as opposed to CFC-12 currently being used. Appendix I, Table X shows that based on 1993 CFC consumption/usage, 1000 kg. of direct use of CFC-12 and CFC-11 will be eliminated. Indirect use eliminatedis much greater. An average of approxirnately1 kg. of initial charge of CFC-12 is used in each CFC-12 MAC fabricated. At an estimated production level of 3035,000 units/yr. in recent years, assuming a total of 2.5 kg./unit of consumption over useful life of the MAC, indirect consumption foregone made possible by the project is 75-90 tons CFC-12 annually. 14. EnvironmentalIssues: There are considered to be no adverse environmental issues associated with this project. Current material washes used in production of evaporator/condensercomponents utilize perchloroethylenevapor degreasers which the United States EnvironmentalProtection Agency (USEPA) has declared a "Health Hazard". New process technology will use washes containing "Day-Trex" developed by S.A. Day Manufacturing, which is nontoxic and enviromnentallycompatible. Perchloroethyleneused for 1992 and 6 months of 1993 production was estimated to be 12,184 U.S. gallons, with 7,000 gallons estimated for 1994 production. The proposed project will eliminate this environmental contaminant.
15. Recommendations: Following a review of all proposals with FAACA personnel, appropriate modificationshave been made in the design and configuration of the relevant production areas of the facility. The Project is found to be technically correct and consistent with FAACA's customer requirements. Furthermore, the project will also allow FAACA to develop designs for FAACA's aftermarket and future AC componentbusiness.
Annex I
Appendix 1: Tables I - X
List of Tables
Table I:
Evaporator/CondenserAssembly Line, Estimated Equipment Costs.
Table II:
Evaporator/CondenserAssembly Line, Estinated Tooling Costs.
Table III:
Evaporator/CondenserAssembly Line, Other Incremental Costs.
Table IV:
Evaporator/CondenserAssembly Line, Recurrent Non-incrementalTraining and Tooling Costs.
Table V:
FAACA Customer Design Changesby Vehicle Model and Change Type.
Table VI:
Present and Future Product Designs Suitablefor HFC-134a Air Conditioner(AC) System.
Table VII:
Evaporator/CondenserAssembly Line, EquipmentRequirements Listed by Customer Model.
Table VIII:
Evaporator/CondenserAssembly Line, Tooling Requirements Listed by Customer Model.
Table IX:
HFC-134a Production at Assembly Plants and Localization Program.
Table X:
Estimationof Direct and Indirect CFC ConsumptionEliminated Through Project Implementation.
Table 1: Evaporator/CondenserAssemblyLine EstimatedEquipmentCosts (US$)
OriginalCost Estimates
Local Built
Probable Retroactive
Future Purchase
Revised Cost Est.
Ref. No.
Description
IE
SerpentineType Tube Bender
2E
CorrugatedFin Machine
3E
SerpentineType AssemblyMachine
2,840
X
US$4,000
4,000
Parallel Flow Type Assembly Machine
2,840
X
4,000
4,000
Ford Evaporator-Crush/Size MachineEvaporator
8,637
X
12,100
12,100
Evaporator- U-Flow Crush/SizeMachine
8,637
X
12,100
12,100
G.M. Evaporator- Crush/Size Machine
8,637
X
12,100
12,100
4E 5E 6E 7E
Imported
Retroactive
US$133,500
X
US$127,500
31,270
X
25,357
Additions
US$127,500 25,357
_
8E
Final Leak CheckLine
125,000
X
209,500
209,500
9E
ChiplessCut-offMachine
75,750
X
75,500
75,500
13,975
X
IOE Tube End ClosingMachine
13,975
13,975
1IE
DegreaserLine
98,000
X
110,000
110,000
12E
G.M. HeaderTube Center (HTC) CondenserFlux & Crimp Machine
95,000
X
95,000
95,000
i 0.
-
Ref. No.
l
_
Description
_
Original Cost Estimates
--
Imported
Local Built
_
___
Retroactive
Probable Retroactive
Future Purchase
Additions
Revised Cost Est.
13E
Reform/StretchMachine
14E
SerpentineDesign Assembly Machines (5 @ $4,000 ea.)
n.a.
X
Parallel Flow Assembly machine
n.a.
X
4,000
4,000
US$4,000
Roller Machinefor Tube End Form
n.a.
X
51,375
51,375
US$51,375
SUBTOTAL COSTS
US$647,586
US$218,357
10% FREIGHT-Imports
61,549
21,836
1,397
54,137
US$77,370
Total Cost
709,136
240,193
55,472
623,712
US$919,377
15E 16E
65,500
X
65,500
65,500 20,000
US$54,075
20,000
US$569,575
US$75,375
US$20.000
US$842,007
Table II: Evaporator/CondenserAssemblyLine EstimatedTooling Costs (US$) Ref.
Original Cost
No. IT
Description
Qty.
Estimates
Local
Imported
Built
Retroactiv e
Probable
Future
Retroactive
Purchase
Revised
Additions
Cost Est.
Fin ToolingSerpentineType (SPT) Condenser 16MM Hght
I
US$10,025
X
US$8,301
US$8,301
1
8,425
X
6,609
6,609
1
15,650
X
Condenser 8MM Hght
1
9,932
X
Fin ToolingU-FlowEvaporator 10MMHght
I
17,700
X
6T
Fin Tooling Ford Evaporator
1
86,625
X
14,045
14,045
7T
RefrigerantPlate StampingDie Ford Evaporator
1
202,090
X
87,962
87,962
G.M. Evaporator
1
75,000
X
RefrigerantPlate StampingDie UFlow Evaporator235MM
1
95,000
X
RefrigerantPlate StampingDie UFlow Evaporator245MM
I
110,000
X
2T
Fin ToolingSPT Condenser13MM Hght
3T
Fin ToolingSPT Evaporator16MM Hght
4T 5T
8T 9T IOT
15,650
15,650
Fin Tooling Parallel Flow (PF) 9,932
9,932
17,700
17,700
RefrigerantPlate StampingDie 75,000
75,000
> o 0.
Ref. No.
Description
Qty.
Original Cost Estimates
Imported
Local Built
Retroactiv
Probable Retroactive
Future Purchase
Additions
Revised Cost Est.
e
I IT 12T 13T 14T 15T
RefrigerantPlate StampingDie UFlow Evaporator255MM
1
120,000
End Plate StampingDie Ford Evaporator
1
20,432
X
End Plate StampingDie G.M. Evaporator
1
17,557
X
17,557
17,557
End PlateStampingDie U-Flow Evaporator235MM
I
24,659
X
24,659
24,659
Evaporator 245 & 255MM
1
26,250
X
26,250
26,250
Toolingfor End ClosingTube HeadersPF Condenser
1
Hole StampingDie PF Condenser Headers 16MM Tube
1
35,000
X
35,000
35,000
1
35,000
X
35,000
35,000
1
35,000
X
35,000
35,000
1
4,000
X
4,000
4,200
X
4,200
X
138,000 20,432
138,000 20,432
Plate StampingDie U-Flow
16T 17T 18T 19T
105
ExtrusionDie for 16MMMultiport PF Condenser
22T
105
Hole StampingDie PF Condenser Headers G.M. Type
21T
X
Hole StampingDie PF Condenser Headers 18MM Tube
20T
105
ExtrusionDie for 18MMMultiport PF Condenser
.
4,000
4,200
IV 'I
Ref. No. 23T 24T 25T
Description
33T 34T
Additions
Revised Cost Est.
12,500
ExtrusionTube BendTooling for SF1' 16MMFin
1
12,500
X
12,500
12,500
1
1,450
X
1,450
1,450
I
1,480
X
740
7 70_
100
3,335
X
100
12,475
X
12,475
12,475
100
3,335
X
12,475
12,475
100
3,335
X
12,475
12,475
100
3,335
X
12,475
12,475
ExtrusionDie for 5MMMultiport ExtrusionDie for 3.6MM Multiport BrazingFixturesfor Ford 12,475
12,475
BrazingFixtures for G.M. Brazing Fixturesfor U-Flow Brazing Fixturesfor U-Flow Brazing Fixturesfor U-Flow _______
32T
Future Purchase
12,500
Evaporator 245MM
31T
e
Probable Retroactive
X
Evaporator 235MM
30T
Retroactiv
12,500
Evaporator
29T
Local Built
1
Evaporator
28T
Imported
SPT 13MM Fin
Tube SPT Condenser
27T
OriginalCost Estimates
ExtrusionTube BendTooling for
Tube SPT Condenser
26T
Qty.
Evaporator 255MM
Plastic HousingInjectionMold Set Ford Evaporator
3
300,000
X
Plastic HousingInjectionMold Set Toyota Corolla
2
160,000
X
3
23,000
X
75,000
75.000
160,000
160,000
Vibration WeldingFixturePlastic Housing Ford
56,040
56,040
0 i
Ref No. 35T 36T 37T 38T 39T 40T 41T
42T 43T 44T
45T
Description
Qty.
Original Cost Estimates
Imported
Local Built
Retroactiv e
Probable Retroactive
Future Purchase
Additions
Revised Cost Est.
Tube Cut Off Tooling Micro Multiport Tube 16MM
I
8,400
Tube Cut Off Tooling Micro Multiport Tube 18MM
I
n.a.
AluminumExtrusion Die for G.M. PF Condenser Tabs
1
400
X
Stamping Die for G.M. PF Condenser Tabs
1
6,336
X
StampingDie for Upper Shell U-Flow Evaporator Inlet/Outlet
I
15,000
X
21,000
StampingDie for Lower Shell U-Flow Evaporator Inlet/Outlet
1
15,000
X
21,000
Plastic Injection Mold Set for SPT Condenser Headers - Toyota, Corolla
1
90,000
X
94,000
94,000
Plastic Injection Mold Set for Civic Evaporator Housing
1
153,000
153,000
153,000
Stamping Die - Upper/Lower Deflector Inet Manifold
1
30,000
X
42,000
42,000
Forming Die for Header Tab Location - Header Tube Center (HTC) Condensers
1
5,150
X
Forming Die for Header PF Condenser 16MM
1
4,500
X
X
8,400
8,400
400
400
_
6,336
X
7.200
6,336 21,000
_
_21,000
7,200
X~~~~~~~~I 6,300
6,300
Ref. No.
Description
Qty.
Original Cost Estimates
Imported
Local Built
Retroactiv e
Probable Retroactive
Future Purchase
Additions
Revised Cost Est.
Forming Die for Header PF Condenser 18MM
1
4,500
End Form Die Set for 8MM Tube Pipe
1
4,000
X
5,285
5,285
End Form Die Set for 1/2' Tube Pipe
1
4,000
X
5.285
5,285
Pipe
1
4,000
X
5,285
5,285
Tube Bender 3.6MM x 4.15MM Radius
1
4,650
X
4,650
4,650
51T
Tube Bender for 5MM Tube
1
4,650
X
4,650
4,650
52T
Die Set for InletiOutlet Manifold SPT Condenser
_
n.a.
Progressive Die for End Plate Reinforcement- Ford Evaporator
I
n.a.
46T 47T 48T 49T l_____
50T
53T
6,300
6,300
X
End Form Die Set for 5/8' Tube
SUBTOTALCOSTS 10% FREIGHTon Imports TOTAL COSTS
12,000
X X
3,659
12,000
12,000
3,659
3,659
$15,659
$1,362,757
US$1,933,681
$252.488
$230,288
$879,971
144,442
22,622
7,855
72,751
103,228
2,078,123
277,737
238,143
952,722
1,465,985
olQ _
Table III: Evaporator/CondenserAssembly Line Other Incremental Costs
[
Description
(I) GM Licensing Agreement Investment:Curr. Lic. Agreement
-
ORIGINAL COST EST.
ACTUAL EST. TOTAL COSTS
ACTUAL RETROACTIVE
PROBABLE RETRO.
FUTURE PURCHASE
$89,000
$215,500
ADDITIONS
REVISED EST. COSTS
US$314,500 ($10,000)
$304,500
22,795
(2) SANDEN Licensing Agreement
32,825
$55,620 US$360,120
$304,500
TOTAL LICENSING COST (3) Training (Per License Agreement)
- 2 Trips GM Personnel to -
-
Venezuela @ US$5,000 each
$10,000
Training of FAACA Engineersat Lockport, New York for 4 People @ US$5,0.0040hrsl*4
$20,000
$10,000
$5,000
Training of one FAACA Engineer at SANDEN/Japan@ $12,000.
$15,000 $12,000
$12,000
(4) Training FAACA Engineers at Tool l
Manufacturing Plant Sites in U.S. -
Tube Bender Equipment
$5,000
-
Chipless Tube Cut Off Machine
$5,000
$5,000 _
TOTAL TRAINING COSTS
S40,000
TOTAL OTHER INCREMENTALCOSTS
$344,500
l $5,000
l
$520,000 $121,795
$290,325
$67,620
$412,120
-
>
Appendix I Page I of 2
Table IV: Evaporator/Condenser Assembly Line Recurrent Non-incremental Training and Tooling Costs (US$) No.
DESCRIPTION
DETAIL
I
EQUIPMENT INSTALLATION
2
PLANT REARRANGEMENT
3
Training of FAACA Personnel (General Plant Training) 100 People @US$50for 20 Hours
4
5 6
Machine Operator Training: 3 People @US$100per week - 2 weeks 7 People @US$50 per week - I week Training of New Hires AssociatedWith Project: 50 People @USS50 for 20 Hours
100*S50
TOTAL
US$18,750
USS18.750
US$5,700
US$ 5,700
US$5,000
3*200=$600 7*$50=$350
950
50*550
2,500
TOTAL TRAININGINVESTMENT
7
SUBTOTAL
(3 +4+5)
US$ 8.450
ADDITIONALTOOLINGCOSTS CondenserBracketry: * Ford Bronco Right/Left End Plates 2 Lower MountingBrackets 2 Upper Manifold Mounting Brackets Two Manifold Clips * Ford Festiva Four Mounting Brackets Two Manifold Brackets Fan Motor Brackets Side Plate
US$32,000 17,000 19,500 4.8 73,300
I ______________________________________________
US$22,000 12,300 17,200 4.800 56,300_______5_30 S_____________
* G.M. Blazer / S-10 Manifold Brackets Side Plate _ _____________________________________________________
US$12,500 6.300 18,800
* G.M. Swift 1.3 Liter Right/Left End Plates Four Mounting Brackets Dehydrator MountingBracket Inlet Manifold Bracket * G.M. Swift 1.6 Liter Four Mounting Brackets Side Plate
US$27,000 23,500 15,000 4.200 79,700 US$28,000 5.S00 33,500
.
-
Ac,vendix I
Page 2 of 2
No.
DESCRIPTION
DETAIL
* MitsubishiMontero Four Mounting Brackets Side Plate
SUBTOTAL
TOTAL
US$25,800 6.300 32,100
* Mack Civic Four Mounting Brackets Fan Motor Mounting Brackets Inlet/OutletManifold Brackets
US$23,000 9,500 10.8 l___________
43,300
* Toyota Corolla Dehydrator Mounting Bracket
US$11,800
* Toyota FJ80 Four Mounting Brackets
US$28,500
* Toyota FJ70-75 Four MountingBrackets Dehydrator Mounting Bracket
US$26,300 12,350 38,650
* Chrysler LeBaron Right/Left End Plates Four Mounting Brackets Manifold Bracket Side Plate
US$26,500 20,250 8,875 1.875 57,500
TOTAL CONDENSER TOOLING
8
9
10
US$473.450
CONDENSERFINAL DIMENSIONAL CHECKINGFIXTURES 11 Cores x US$1,830
11*$1,830
US$20,130
US$ 20.130
EVAPORATORINLET OUTLET MANIFOLD WELDINGFIXTURES(3 Fixtures per Core) 11 Cores x 3 Fixtures @US$1,150)
11*3* ($1,150)
US$37,950
US$ 37.950
US$2,900
USS 2.900
ADDITIONALEQUIPMENT REQUIREDFOR: - ConvertingSalt Spray Chamber - Performing CustomerRequired 'SWAT" Corrosion Test TOTALFAACA INVESTMENT
US$567.330
Appendix I Page I of 1 Table V: F.AACA Cuistoin-r DesikmChanges by Vehicle Model and Chanee Tvpebt
CHANGE TYPE CUSTOMER
MODEL(S)
Ford Motor Company
-
General Motors De Venezuela
-
-
I
Bronco F150 Festiva
X
A-Car S-10 Blazer - Swift 1.3 L - Swift 1.6 L -
Mack De Venezuela
- Trooper
X
- Corolla
Venezuela
- FJ62 (FJ80)
X X
2,000
X
5,000
X
3,000
X
12,000 5,000 2,200
X
X
- Spirit/Lebaron
_
X
Lada
-
Niva 1500 1200 1600 Sontana
X X X X
Fiat
- Uno 1500 -PreH101600
X X
Total Estimated Design Changes b/
8,000 4,000
(Civic)
- FJ70-75 Chrysler De Venezuela
QTY/YEAR
1,500 4,000
X
Delica (Montero)
Toyota De
v
X
-
Mitsubishi De Venezuela
_ _i|I_
|nII
ESTIMATED
3,500
51,200
Types of changes are classified for presentation purposes on a scale of I to IV as follows: I. 11. III. IV.
Carry over model with minor changes in AC system for HFC-134a applications (current Production). Carry over models with complete AC component design changes in HFC-134a change over. Car line model substitution with complete changes in the AC system. New Models designed for CFC-12 already submitted for customer validation that need major changes for HFC-134a application.
Appendix I Page I of I Table VI: Present and Future Product Designs Suitable for HFC-134a Air Conditioner (AC) System
EVAPORATORS (DESIGN) * Serpentine Type
* Plate and Fin (Conventional)
DESIGN CHARACTERISTICS
I 90x5 MM 104x5 MM I00x5 MM 85x5 MM Center Length
16 F/H MM 22 F/H MM 19 F/H MM 16 F/H MM Fixisize
A
Ford 92x269 MM
93 F/H MM
B
Parallel Rib Staggered Rib - Long Staggered Rib - Short
C
Plate Size 9.7 FIH MM Plate Size 9.7 FiH MM Plate Size 9.7 F/H MM
D E F
GM
* U-Flow
HFC-134a APPLICATION
235x90 MM 245x90 MM 255x90 MM
CONDENSERS (DESIGN)
DESIGN CHARACTERISTICS
HFC-134a APPLICATION
* Serpentine Type
Conventional Compact
22x5 MM 22x3.6 MM
G H
* Parallel Multiflow
Headered Tube Ctr Standard Standard
16x2 MM - 8 F/H MM 16x2 MM - 8 F/H MM 18x2 MM - 8 F/H MM
I J K
CUSTOMER VEHICLE MODEL
DESIGN APPLICATION EVAPORATOR
CONDENSER
Bronco
B
H
Festiva
D
i
A-Car
c/o
c/o
SIO/Blazer
C
I
Swift 1.3 Liter
E
G
Swift 1.6 Liter
E
K
E (Front)
K
Montero (Dual System) ______________
~~~A (Rear)
K
Civic
D
J
Corolla
F
H
FJ80 FJ70/75 Chrysler LeBaron
H c/o
H H
TABLEVII: Evaporator/CondenserAssemblyLine EquipmentRequirementsListed by CustomerModel TOTAL NUMBER
FORD BRONCO
EQUIP. REF.NO. IE .
FESTIVA
........
X .
2E.
X
.
.
.
.
9h ....
. .
.
.
.
.
~.
.
........
.
X
6E ....................
.
.
.
.
.
X .
.. .
.
..
.
.
X .
.,X ......
.
.
X ..
....
*IIE.....
.
.
.
.
.
.
.
.X ..
.
.
.
. .
.
..X ..
.
. X
.
.
X ..
.
..
.
.
.
.
.
.
..... ,,,., .
.. . . ... .
.
.
. .
.
.
.
,.
X
.
. ,
.
.
.
.
. X .......
,..
.
.,
..
..
X ....
.... ,,X....
.
.
.
.
.
.
.
.
,
. .
.
X
..
.
X, ....
. X
. S
.
.
.
..
.. .
.
...
..
.
.
.
X .. .
.
.
.
.
.
.
.
.
. X .
.
.
.
.
.
.
..
.
.
.. X .
.
.
..
.
.
.
.
.
.. X _ .
.
.
.
.
.
.
.
. .
.
. .
. .
.
.
I . 12
. 4
... ,
X .
X
Mitsubishi Motors Corporation.
* Item 8E:
Current Plant Process Leak Test = CFC-12. Mass-spectrometer Test Utilizes Helium Radier than CFC-12. New Test will eliminate all ODS CFC-12 used in building of Evaporators/Condensers.
0 Item
Current process utilizes Perchloroethylene
.. X ...
~
~
..
X ..
.
.
I
...........
I .
1
X ........
.....
X
,.................................................
- new process will use 'Daytrex'
.
.
.
..... ....X
X
, .
6
.X ....
6
............
X
X
,
..
.
X .. I
.
X .X
....... 5
.
.
.
7
. . .. . .. . .. . . . . . . .. . .. .. . . . . ., . . . . .. . . . . .. . . .. . . . .. . . . I
.
.
.
.
........
X .........
X.
X
* MMC:
I I E:
X.
X, x....... ...... X
x
x....
.
X
X.
X.
X........... X
12E .................... .
X .
OF CUSTOMER APPLICATIONS
CHRYSLER LEBARON
FJ70-75
X.X
X ...
OE .
13E .
.
....., ......... .. .... ..... ,,,,......
'8E1... ..
x .
XX..
....
X .X
7E X... .....
FJ80
X..
4E. . . .. . . X . 5E . ., ,,..
TOYOTA COROLLA
.X ......
X
.....
..........
X...
3E .
..
X
MACK CIVIC
MMCMONTERO
SWIFT 1.6 1.3
S-10 BLAZER
GM A-CAR
.
X .
.
.
7
..
developed
by S.A. Day Mfg. (nontoxic)environmentallycompatible. Leak Process CFC-12. Plant SE:Current *Test Item
~
~
~
~
~
~
~
~
~
~
~
_
o>.
TABLE Vm: Evaporator/CondenserAssemblVLine Tooline Requirements Listed by Customer Model TOOLING REF.NO. I ...
.
TOTAI. NUMBER
FORD BRONCO .
.
.
2
.
FESTIVA
GM A-CAR
. ..... ....
.....................
. .
. ..
4.
.
5 . . . . .
S
. .
. .
. . . . . . . .
. .
.
.
.
MACK CIVIC .
.
.
.
TOYOTA COROLLA . .
X
,,
.
.
. X . .
X .
.
.
FJ70-75 .
.
X.X . .. X ..
OF CUSTOMER APPLICATIONS
........................
X
5
X
. . . ....---..-.---. - --.... . . . . . . . . .
. X .,
F180
CHRYSLER LEBARON
. . . .
..
..
..
..
. ..
..
..
..
. .-
.. . . . X ..
5 . . X .
. . . .
. . . . . . . .
. . . . .
. .. 6
x.....
I
,....
X
.2............
....
10
MMC MONTERO
.. X...
...
9 ....
. . . . .
.
. . . . . .X . .
.
...
. . . . . . ..
.... X
SWIFT 1.3 1.6 x
.. .
X
3 *-... . . . .
S-10 BLAZER
.x.
X
11
2 3
........
I
12X. ..........X .......................... ..................................................................................... ,.. 13 14.... I,
X
...
,
X..
....... ....X....
15.
.
I.....I
.
X
X.
.
19....
X .. .
.
X . .X X
.
X .
. ...................
.........
1 20 . . .
X.
..... .. .
. .. . .
X
.
X.....
. . . . . . . . . . . . , .. . . . . . . . . . .
2..X.X.X.X.X.,, 6 2...
.... . .. . . . . . .. .
2 I.. . . . .. . .
. . .. . . .
. . .... . .
.. . . I 19 >S rQb
-
_
TOOLING REF.NO.
FORD BRONCO
FESTIVA
MACK CIVIC
MMC MONTERO
SWIFT 1.6 1.3
S-10 BLAZER
GM A-CAR
TOYOTA COROLLA
FJ70-75
FJ80
CHRYSLER LE8ARON
2
X......x
21 ...........
X..XX......
.
22 ,.....
3
-
.
.
24 ,,,..,..,,,,.......2..
26 .
X .,.
27.
X
x
..........
.
..
,.I
.,
.,,,,
25 .,....................
5
.2
x.x
.
.
X.X.
X
X
,,,,........
X ...
23.
x
...... 1
.......
....
I
29.X.........
X .. X
.....
.2
.
, ,
X,
30
5
X
x.....
,.....x.......
28
x......
..
2 3
Ix
31,,.....,....... 32.
,
X
I
,......,.,,,............,,.........
I
33X.... 34
TOTALNUMBER OF CUSTOMER APPLICATIONS
.
,,,
X.,,
,2
35.X.X., 366.,.X.XX..3 37.,,....I
...............
38 ........... 39 ... 39 . ... ..
.....
X .X. ..
..
..
..
....,.,,. ............. 40.X..X.X
.
.
.
X
X .
.
.
.
.
.
.
.,,,,,,.,.
..
.I
.................4 .............. . X.X....... . . . . . . . . . . . . . . . . . . . .. 4 o X .. . . . X X.4~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~t
..
10 -.3(
TOOLING REF.NO.
FORD BRONCO
FESTIVA
GM A-CAR
S-10 BLAZER
SWIFT 1.3 1.6
MMC MONTERO
41......... 42.
FJ80
FJ70-75
CHRYSLER LEBARON
TOTAL NUMBER OF CUSTOMER APPLICATIONS
........ X
44
X
X
3
X. .........
45X.
................... X
I
,
... X ...
50..... 51........... X
2 X......2
47....... 48.
TOYOTA COROLLA X....I
43...............
46.
MACK CIVIC
.....
X.X
X X
.6
X XXX..4
X X
X
X
X
5
i>. as *
T
IEAR
1%3"
noctLs~~~~~~~~~~~~~~
otC134a
H
f
Ev ym"*t |||||||t.''6t...tA8'':e, %MO^
hlLl
EsSiD
|
iti|
;
$t
_
,-,6o
~~~~fR7. EVAP3RATOq RP~~~~ -CAIDENSER
^ $+st-*Zf.-$-t.}Ui. |
hOcfMDAg C_W WC 1LIn-r v1 f=
,
p
-
EVAP014-OP
,
~HCOC34
HFC-134a1
5
-
^
9
5xi
:H .'i0t|
1lt
4
\
1
'0CAOZA-i O CCE,RA 4CEt
rfi-70/CJ,eJ
!a
KC-$ qN\34A0A
IIIII1.31 1.6 2
tOCAUtZATIC
|~~~~
E
fiSRXBE ~~~~~~CC'CfY5;-R ..........
,LOCAU!ZAT01
J||S|G@M|D!!
E-VNpORATO0r 3l-lf-l._ ......
!
j
_
FrII[f
-T(:)PRAR_I_
ST,V OfAVATPI
g
rlnl) JIASC
1I. s
cOCALIZA,
[jif
_
